A/C System Filtering
Set, A/C Fittings:
Special Tools
WARNING:
^ R-134A IS CLASSIFIED AS A SAFE REFRIGERANT, BUT MISUSE CAN MAKE IT DANGEROUS. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED.
^ ALWAYS WEAR SAFETY GOGGLES WHEN REPAIRING AN AIR CONDITIONING SYSTEM.
^ AVOID CONTACT WITH LIQUID REFRIGERANT R-134A. R-134A VAPORIZES AT APPROXIMATELY -25°C (-20°F) UNDER ATMOSPHERIC PRESSURE AND IT WILL FREEZE SKIN TISSUE.
^ NEVER ALLOW REFRIGERANT R-134A GAS TO ESCAPE IN QUANTITY IN AN OCCUPIED SPACE. R-134A IS NON-TOXIC, BUT IT WILL NOT FURNISH THE OXYGEN NEEDED TO SUPPORT LIFE.
^ NEVER USE A TORCH IN AN ATMOSPHERE CONTAINING R-134A GAS. R-134A IS NON-TOXIC AT ALL NORMAL CONDITIONS, BUT WHEN IT IS EXPOSED TO HIGH TEMPERATURES, SUCH AS A TORCH FLAME, IT DECOMPOSES. ONE OF THE PRODUCTS OF THE CHEMICAL BREAKDOWN IS A PHOSGENE GAS, WHICH IS HIGHLY TOXIC.
^ DO NOT ALLOW ANY PORTION OF THE CHARGED AIR CONDITIONING SYSTEM TO BECOME TOO HOT. THE PRESSURE IN AN AIR CONDITIONING SYSTEM RISES AS THE TEMPERATURE RISES AND TEMPERATURES OF APPROXIMATELY 85°C (200°F) CAN BE DANGEROUS.
CAUTION: A/C system filtering must be performed as part of an A/C compressor replacement to remove any debris that could result in premature system failure.
NOTE: An A/C service kit has been released to provide the necessary equipment and information to perform the new, mandatory A/C system filtering procedure.
1. Determine if the A/C compressor has failed and must be replaced.
^ Look for an A/C evaporator core orifice or a condenser to evaporator tube containing black refrigerant oil and particles.
2. Replace the A/C compressor.
NOTE: Make sure the proper amount of refrigerant oil has been added to the A/C compressor prior to installing it.
3. Replace the suction accumulator/drier.
NOTE: Make sure the proper amount of refrigerant oil has been added to the suction accumulator/drier prior to installing it.
4. Get the proper A/C service kit for the vehicle being serviced.
^ Nylon refrigerant lines have a wall thickness of 3.175 mm (1/8 inch).
NOTE: An A/C service kit with the service part number suffix A is used on vehicles with a nylon-lined evaporator.
5. Remove a length of the evaporator-to-compressor suction line to accommodate the suction filter.
6. Install the O-rings on the filter tubes.
NOTE: The O-rings are installed in the suction filter only for nylon-lined refrigerant lines. Two O-rings must be seated in the grooves on each filter tube for proper sealing.
7. Install the (A) filter on nylon refrigerant lines and the (B) filter on all other refrigerant lines.
NOTE: Check the suction filter label to make sure the filter is installed in the same direction as the refrigerant flow.
8. Install the clamps and tighten securely.
9. NOTE: If the A/C evaporator core orifice is located in the condenser-to-evaporator tube, replace the condenser-to-evaporator tube.
Install a new A/C evaporator core orifice.
10. Install a pancake filter.
^ Use the A/C Test Fitting Set and flexible refrigerant hose (minimum 144796 kPa [2500 psi] burst rating).
NOTE: Make sure the filter inlet is facing toward the A/C condenser core.
11. Evacuate, leak test, and charge the A/C system. Evacuation
12. Check all the refrigerant system hoses, lines, and the positioning of the newly installed filters for any interference with the engine.
^ Use tie straps to make adjustments.
13. Provide adequate airflow to the front of the vehicle.
NOTE: It may be necessary to operate a high volume fan to blow air through the radiator and A/C condenser core to aid in engine cooling and to prevent excessive A/C system pressures.
14. Set the A/C-heater function selector switch to MAX A/C.
15. Set the heater blower motor switch to HIGH.
16. Set the temperature control switch to full COOL.
17. Start the engine and let it idle briefly.
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA.
18. Check the A/C system for leaks.
19. Gradually raise the engine speed to 1000 rpm, and then to 1200 rpm.
20. Set the engine at 1200 rpm for one hour.
21. Stop the engine.
22. Recover the refrigerant.
23. Remove the fittings, flexible refrigerant hoses, and the pancake filter. Discard the pancake filter.
WARNING: ALLOW THE ENGINE TO COOL SUFFICIENTLY PRIOR TO PERFORMING MAINTENANCE OR SERIOUS BURNS AND INJURY CAN OCCUR.
NOTE: The pancake filter is a one-time use only item. It must be discarded after each use.
24. Evacuate, leak test, and charge the A/C system.
25. Check the climate control system for proper operation in all of the functions.